Process for molding a fiberglass reinforced article

ABSTRACT

A process for producing fiberglass reinforced molded articles of superior surface quality involves preparation of a mat of glass fiber comprised of a majority of fibers having a diameter of less than one micron and a minority of fibers having a diameter greater than one micron. A sizing is applied to the fibers. The sizing includes a coupling agent preselected to be compatible with the moldable material, e.g. nylon. The glass fiber mat is comminuted into pieces shaped and dimensioned for combination with the moldable material to form a composite having a range of to 50% of glass fiber by weight. The composite is then molded by a conventional process to yield a fiberglass reinforced article with superior surface quality.

TECHNICAL FIELD

This invention relates to a process for producing fiberglass reinforcedmolded articles of superior surface quality.

BACKGROUND ART

Fiberglass is used to reinforce molded articles molded of plastic andelastomerics to enhance their mechanical strength and dimensionalstability over thermal operating cycles.

The mechanical strength of a fiberglass reinforced plastic article has adirect relationship to the quantity of fiber glass contained within themoldable plastic. Also, the thickness of the glass fibers contributes tothe mechanical strength of the article.

However, as the thickness of the glass fiber increases so does itsprominence and visibility in the surface of the plastic molded article.A relatively coarse glass fiber impairs the smoothness and appearance ofthe surface of the article, and makes it unacceptable for productapplications which require high surface quality, such as exterior bodypanels and trim components of automobiles unless additional processes ormaterials are used to finish the surface.

The prior art has addressed the problem of surface quality degradationby glass fiber reinforcement by techniques which are intended to maskthe reinforcing fibers. These techniques increase the complexity andcost of manufacturing fiberglass reinforced plastic articles in highvolume at commercial quality levels.

The service demands and operating environments of many plastic moldedarticles, such as automotive body panels and trim pieces, requiremechanical strength and thermal stability which may be achieved byfiberglass reinforcement. The difficulty with the use of fiberglass inthe molding of such articles has been its degradation of their surfacequality.

The practical problem thus defined is the molding of a fiberglassreinforced plastic article Which enjoys the superior mechanical strengthand thermal stability contributed by fiberglass without the impairmentof surface quality. This problem is the subject of the publishedJapanese Patent Application titled "Glass Fiber-Reinforced ResinComposition," Application No. 60-21947, filed Feb. 8, 1985 by HiromichiUohashi and Tetsuji Kodaira, and published Aug. 16, 1986. Thatapplication discloses a glass reinforced plastic composition whichemploys glass fibers of diameter and length below preselecteddimensional limits.

However, the patent does not address the problem of mixing the fiberswith the plastic so that they become consistently spread throughout theplastic material. This problem is particularly acute with micro-fibers.The small, hair-like nature of such glass strands makes theirintermixture with polymer resins difficult. Moreover, clusters of suchfibers are not easily separated in a viscous polymer emulsion to providea homogeneous dispersion of fibers in the polymer.

DISCLOSURE OF THE INVENTION

The present invention addresses the problem of surface impairment byfiberglass reinforcement of plastic articles by providing a process inwhich glass reinforcing fibers are combined with a moldable material toprovide a composite with sufficient density and homogeneity of the glassfibers to ensure thorough mixing of the fiber with the moldable plasticto improve mechanical strength and thermal stability over previouslyknown micro-fiber composite materials without substantial impairment ofsurface quality. The invention uses the characteristics of high surfacearea, resiliency, and large aspect ratio of fine diameter glass fibersto provide property enhancement to plastic and elastomeric moldablematerials.

The inventive process involves preparation of a mat comprised of amajority of glass fibers having a diameter of less than one micron, anda minority of glass fibers having a diameter greater than one micron.The submicron glass fibers are the dominant constituent of the bulkglass reinforcement material, and their density in the mat is matched tothe mechanical strength and thermal stability requirements of the moldedarticle. The presence of a minor portion of glass fibers of diametergreater than one micron is for the purpose of providing a carrier forthe sub-micron fibers. The quantity of such larger diameter fibers isselected to be the minimum required to carry the sub-micron fiberswithout substantial surface impairment.

The glass fibers are treated with sizing to enhance the intermixture ofthe fibers with a polymer. The binding of the glass fibers to themoldable plastic is also improved by sizing with a compatible material.For example, if the moldable plastic is nylon, a nylon-compatible sizinghaving appropriate selected keying agents, binders, and wetting agents.

The sized, glass fiber mat is then dried and comminuted into pieces ofshape and dimension suited for intermixture with a more substantivequantity of polymer determined by the surface finish and mechanicalstrength specifications of the finished product. In the preferredembodiment, the mixture is prepared for feeding to a plastic moldingmachine such as an injection molder.

The pieces of glass fiber mat are combined with a moldable plastic orelastomeric material in a composite having a range of 2% to 50% of glassfiber by weight. The specific weight ratio is chosen based on thedesired physical properties of the molded article.

Alternatively, the fiberglass reinforced plastic article may be formedas a panel which is stamped or molded to a desired shape havingrequisite mechanical strength and thermal stability without substantialimpairment of surface quality.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic view of the process of the present invention inwhich a fiberglass reinforced article is molded from a composite whichincludes a fiberglass constituent having a majority of glass fibershaving a diameter less than one micron and a minority of glass fibershaving a diameter greater than one micron.

BEST MODE FOR CARRYING OUT THE INVENTION

In FIG. 1 bulk glass fibers 10 are formed into a thin paper sheet or mat14 by a conventional wet slurry process. A pair of rollers 12 indicateschematically the feeding of a slurry of bulk fibers 10 through rollerstations in the mat forming process.

The bulk fibers 10 are constituted of a majority of fibers having adiameter of less than one micron, and a minority of fibers having adiameter greater than one micron. A suitable proportion by weight may be20% of a 3.0 micron glass fiber product and 80% of a 0.65 micron glassfiber product. The submicron diameter fibers may range in diameter from0.2 micron up to 1 micron, and their weight may comprise 50-90% of themat weight. The larger diameter fibers may range in diameter from about3 microns to 18 microns, and they may constitute 10 to 50% of the matweight.

The primary function of the larger diameter glass fibers is as basecarriers for the finer fibers in the wet slurry process, and secondarilyin contributing to the mechanical strength of the molded article. Thepresence of the finer fibers in requisite density lends the preponderantmechanical strength to the molded article.

The glass fiber mat 14 receives an application of sizing, as indicatedschematically by applicator 16. Any number of conventional methods ofapplying sizing may be used. For example, the glass fiber mat may beimpregnated with sizing by either a spray application, submersion in abath, addition of sizing in the wet slurry process, or a curtain coatmethod. Other known sizing application techniques could serve as well,such as precipitate techniques including pH adjustment orpolyelectrolyte addition.

The sizing is preselected to be compatible with the chemistry of moldedmaterial to be used. Typical sizing chemistries include silicones,organofunctional silanes and resin systems that are specific to themoldable material to be combined with the glass fiber. For example, ifthe moldable material is duPont Zytel Nylon/6, the sizing would beselected from a group which uses aminosilane as the coupling agent, forexample, Manville Star Strand 761. Other types of moldable materials,such as polyester, ABS, polypropylene, polyethylene and the like, havecommercially available coupling agents compatible with these materials.Sizings typically have a solids content in the range of 0.1% to 20%, andare applied so that 0.1% to 15% of the weight of the fiberglass mat isdue to the sizing.

In the preferred embodiment, the sizing operation includes coating thefiber with a latex compatible with or the same as the thermoplastic orthermoset material which is to be reinforced by the glass fiber. Forexample, a polyvinyl chloride (PVC) latex will be used to coat fiberintended for reinforcement of PVC product. Preferably, an aqueousslurry, commercially referred to as an emulsion, includes up to 50%latex for treating the bulk fibers 10. In a working example, couplingagents included 0.27% gamma-aminopropyltriethoxysilane, e.g. UnionCarbide A-1100, and 0.18% triaminofunctional silane, e.g. Union CarbideA-1130. These coupling agents were mixed with 0.08% lubricant, i.e.Emerlube 7440, 0.51% film former, i.e. Poly Em 40 polyethylene emulsion,and 98.96% Water to form a sizing for the micro fibers made of E-Glass.Since the slurry is sufficiently dispersed about the fiber, the latexcan coat the fiber to protect it during handling and compounding.Moreover, the sizing of the example, and particularly the couplingagents, would be compatible with a wide variety of thermoplastic as wellas thermoset materials, including but not limited to polypropylene,polycarbonate, styrenes, phenolics and epoxies.

The sized mat 14 can be easily handled and processed as in a choppingoperation. When the mat 14 is comminuted, the fiber is reduced in bulkby an order of magnitude which will aid in the volume of material thatcan be handled in a subsequent mixing operation with the latex material.

Furthermore, the fiber is encapsulated so as to be in a non-rritatingform during handling for the mixing operation. Additionally, thelatex-coated fibers can form an intimate bond with the polymer it isreinforcing. Moreover, less severe processing will be required tohomogenize the coated glass in the latex master batch than would benecessary for bulk fiber.

The sized fiberglass mat 14 is then dried in the oven indicatedschematically at 18.

The fiberglass mat 14 is then comminuted as at 7 into pieces of shapeand dimension suited for combination with the moldable material to allowthe fiberglass to mix and flow in the molding operation. The mat 14 maybe cut into elongated strips, diced into small pieces, or reduced tomatch the size of thermoformable sheets. The size and shape is dependenton the stock form of the moldable material. If the moldable material isto be thermoplastic or thermosetting resin pellets, the fiberglass mat14 will be diced into fine pieces to facilitate the mixing andhomogeneity of the moldable composite, e.g., in pieces about one-halfinch (1/2) square and 0.000-0.100 inch thick. In such a case the dicedglass fiber mat Would be mixed with a controlled quantity of resin 20 ina mixer 22 to produce a moldable composite 24 having the correct ratioby weight of plastic resin to fiber glass to produce a molded article ofdesired mechanical strength and thermal stability.

The . .multiple.!. .Iadd.moldable .Iaddend.composite 24 may be dried ina dryer 26 preparatory to being molded to rid the composite of volatilecontaminants.

In the example of FIG. 1, the . .multiple.!. .Iadd.moldable.Iaddend.composite is a combination of resin pellets and comminutedfiberglass mat pieces which is fed to the hopper 30 of a conventionalplastic injection molding machine indicated by 28. The machine 28 heatsthe composite to the processing temperature of the resin, and theninjects the fluent moldable composite into an injection mold, indicatedat 32. The mold 32 includes mold halves 32(a) and 32(b). The article tobe molded is defined by a cavity 36 within the mold 32. The cavity iscommunicated to the injection nozzle of the machine 28 by a sprue 38.

After completion of the molding cycle, the mold halves 32(a) and 32(b)are separated and the solid molded article 40 is ejected from the mold.The molded article 40 will exhibit superior surface quality withoutsubstantial degradation or impairment by the presence of glass fibers.The molded article 40 will enjoy mechanical strength and thermalstability by the presence of well dispersed glass fiber reinforcement,including the preponderant submicron diameter glass fiber constituent.

Although the process of the present invention has been shown anddescribed in reference to an injection molding application, it isunderstood that the process may be adapted for use with extrusionmolding, sheet molding, bulk molding, and other types of other moldingprocesses and materials which admit to reinforcement of a moldablematerial with glass fibers.

What is claimed is:
 1. A process for molding an article reinforced withglass fiber without substantial impairment of surface quality comprisingthe steps of:preparing a mat of glass fiber .Iadd.from bulk glass fiber.Iaddend.comprised of a majority of .Iadd.smaller diameter.Iaddend.glass fibers having a diameter less than one micron and aminority of .Iadd.larger diameter .Iaddend.glass fibers having adiameter greater than one micron by applying to .Iadd.the .Iaddend.bulk.Iadd.glass .Iaddend.fiber sizing including up to 50% by weight ofpolymer compatible with . .the.!. .Iadd.a .Iaddend.moldable plasticmaterial; comminuting the mat of glass fiber into .Iadd.glass fiber mat.Iaddend.pieces shaped and dimensioned for combination with . .a.!..Iadd.the .Iaddend.moldable .Iadd.plastic .Iaddend.material; combiningthe glass fiber .Iadd.mat .Iaddend.pieces with the moldable.Iadd.plastic .Iaddend.material to define a moldable composite having arange of 2% to 50% of glass fiber by weight; and molding the articlefrom the composite.
 2. The process of claim 1 wherein the majority ofsub-micron glass fibers comprise 50-90% of the weight of the ..article.!. .Iadd.bulk glass fiber.Iaddend..
 3. The process of claim 1wherein the larger diameter glass fibers have diameters in the range of. .6.!. .Iadd.3 .Iaddend.to 18 microns.
 4. The process of claim 1wherein the smaller diameter glass fibers have diameters in the range of0.2 to 1 micron.
 5. The process of claim 1 wherein the article isinjection molded.
 6. The process of claim 1 wherein the moldable.Iadd.plastic .Iaddend.material is a thermoplastic resin.
 7. The processof claim 1 wherein the moldable .Iadd.plastic .Iaddend.material is athermosetting resin.
 8. The process of claim 1 wherein the mat of glassfiber . .product.!. is comminuted by cutting.
 9. The process of claim 8wherein the mat of glass fiber . .product.!. is cut into elongatedstrips.
 10. The process of claim 8 wherein the mat of glass fiber ..product.!. is diced.
 11. An article made in accordance with the processof claims 1, 2, 3, 4, 5, 6, 7, 8, 9 or
 10. 12. The process as defined inclaim 1 wherein said polymer . .is.!. .Iadd.and .Iaddend.said moldableplastic .Iadd.are the same .Iaddend.material.
 13. A process for makingfiber-reinforced polymer products comprising:forming a layer of bulkfiber with a majority of parts by weight of glass fibers of less than 1micron; applying a sizing to said layer of bulk fiber including up to50% of a predetermined polymer, said predetermined polymer beingcompatible with the polymer to be reinforced by the fiber; drying saidsized layer of bulk fiber to form a mat; comminuting said mat intopieces and mixing said pieces with said . .predetermined.!. polymer.Iadd.to be reinforced .Iaddend.to form a moldable composite; andmolding the product from said composite .
 14. The process as defined inclaim 13 wherein said sizing comprises an aqueous emulsion.